How to make hand rollers using tin drawings. Do-it-yourself three-roll sheet bending rollers

Why are rollers needed and what are they? If the design uses a profile pipe, it may be necessary to make it a semicircular or arbitrary curved shape. This is what rolling is used for. This is common practice in specialized factories.

Details about rolling

You can make the pipe take a different shape using a simple torch. This approach is often practiced, but the employee faces a number of difficulties:

there is a need for a large lever to change the shape;
you need emphasis and, as a result, a lot physical strength;
It is almost impossible to make the product even; this is due to inaccurate movements and improper distribution of effort.

To get the best result, you should use rollers. With their help, a profile pipe can be easily transformed with your own hands. The photos and videos show the features of working with the tool. To familiarize yourself with the result of the tool's work, drawings are presented.

1 Type of machine is designed for radius bending of profile pipes.

Characteristics of a standard machine:

The maximum pipe cross-section is 40 x 40 x 2, 50 x 25 x 2 mm.

Minimum circle diameters:

30x30x2 - 650 mm,
40x20x2 - 650 mm,
40x40x2 - 1800 mm,
50x25x2 - 800 mm.

Drive type: manual.

Hardened rollers – all 3 pcs.

Price: 25,000 rubles.

2 Type of machine is designed for radius bending of profile pipes, round pipe and stripes.

Characteristics universal machine :

The maximum pipe cross-section is 40x40x2, 50x25x2 mm.

The maximum cross-section of a round pipe is 32x2.8 mm.

Strip 40x4 mm.

Minimum diameters of a circle of profile pipes:

20x20x2, 25x25x2, 15x15x1.5 –560 mm
30x30x2 - 650 mm,
40x20x2 - 650 mm,
40x40x2 - 1800 mm,
50x25x2 - 800 mm.

The maximum arc diameter is unlimited.

Drive type: manual.

Hardened rollers – all 3 pcs.

Price: 30,000 rubles.

At the Customer's request, for an additional fee, the machine is equipped with a dial indicator for the production of more accurate all subsequent workpieces.

For an additional fee, the machine can be equipped with a 220-380V electric drive

2 year warranty

Contacts:

Tel: 8-919-831-25-14

Saratov region Engels

Delivery within the Russian Federation.

Industrial and home rollers

Not all modifications of this amazing tool can be used at home. How do you think a profile pipe is made? Of course, with the help of rollers. This is done as follows. The sheet of metal is rolled into a cylinder and the seam is welded. Next, the pipe is passed through rollers. Under the influence of high pressure, the desired profile is obtained.

To do the work, enormous effort is required, so the profile pipe is produced using special equipment. Rollers installed in factories weigh more than ten tons. How can you do this kind of work yourself?

We do it ourselves

At home you will need other rollers, not so heavy. Drawings and photos of some modifications are presented on the website. To do the job yourself, you will need a small, mobile tool. Home rollers are available mechanical and electric. Here you have to choose between saving energy and the amount of effort expended.

Electrical appliances “eat” electricity, but making a profile pipe with your own hands is much faster, it turns out like it came from a factory. Mechanical analogues are not inferior in results, but the worker has to apply force to change the shape of the workpiece. In case of electrical appliance There is one more pitfall. Its power can be so high that the aluminum wiring simply cannot withstand it and burns out. This is worth remembering. Electric rollers are available in different versions, but the most popular are those with motors ranging from 500 to 1500 W.

Manual devices are no less in demand. You can make them yourself. To do this you will need three rollers made of durable steel. Two of them are located on the same plane. A handle for rotation is attached to one of the rollers. The third is lowered from above using a simple worm gear. The profile pipe changes shape as a result of pressing its surface during rotation. Drawings of the instrument circuit are presented here.

If you do not plan to make products for sale, homemade rollers- exactly what is needed. It is very cheap, the device is compact, and if necessary, you can also screw in the drive - the device will be electric. In this case, it is important to calculate the power that will be required during rolling.
http://www.youtube.com/watch?v=b4NSJo-FZNY
If the pipe is not profiled, then it can also be bent. To do this, a groove is cut the right size. If you plan to use an electrical appliance, then during its manufacture you should also calculate the gearbox. Thanks to the optimal gear ratios, the forces on the motor shaft are minimized.

We are all a little Kulibina

It is human nature to create. The desire to do something on their own never leaves even the laziest people. When designing rollers, it is worth keeping safety in mind.

Rollers are one of the most important equipment in metallurgical production. They help bend metal sheets, pipes, and other oval and other shaped parts. In addition, rollers are used in jewelry to accurately bend products.

Below we will tell you what rollers are, how three-roll models differ from four-roll models, and how to make them yourself.

Rollers: operating principle

The key working mechanism of the device is a rotating cylinder through which hot sheets of metal are passed and bent. Rolling machines can be equipped with cylinders from 2 to 5 pieces, but three-roll and four-roll products are most often used.

The parts are bent through the action of the third rear shaft, and the fixing radius depends on the distance between the upper and rear shaft.

Sometimes metal rollers break and require replacement. When working with iron, the machine must be constantly heated, and the layers of iron after the rollers go into the furnace, they are heated there, and then pumped again. After that they go back to the machine.

After roller processing cross section metal decreases, and it becomes longer under the influence high temperature metal and degree of pressure.

To obtain a cylindrical product, the rear shaft must be adjusted parallel to the front one, and to make a cone, the rear shaft must be set at an angle relative to the front one.

There are roller models that can be used to process metal directly on the table, but they are not very functional. You can work with them simplify with fasteners. The cost of rollers depends on their dimensions. And if you decide to make the machine yourself, you will save a lot.

The functions of modern rolling machines, home-made and factory-made, three-roll and four-roll, are as follows:

the ability to bend pipes up to 160 degrees;
working with metal pipes;
deformation of pipes regardless of their diameter.

Areas of application of machines

Roller mills are widely used in the production of things such as:

chimneys;
air ducts;
pipes;
ventilation systems;
gutters.

Thanks to its compact dimensions, rollers can be used anywhere, right at the construction site, and hand-held instruments will not damage polymer coating metal

For Food Industry crusher-type rollers are used, and for chemical processing - sheet bending, sheeting and others.

Features of machines for metal

Without a rolling machine it is impossible to give sheet metal a cylindrical shape, and pipe rollers help to arrange a drainage system. Machines with forging cylinders are needed for cold bending of metal blanks; also, thanks to rollers, you can process:

plastic;
ductile metal;
rubber compounds.

You need to choose one or another machine depending on the thickness of the metal:

twin rollers include two parallel shafts, the upper one has a small cross-section and is made of high-strength steel, and the lower one has a large cross-section and is made of rubber-coated steel. Depending on the pressure force of the pipe, its outlet diameter is selected;
three-rollers can be symmetrical or asymmetrical, they are often used in the production of ventilation, round drains and radius parts. In addition, three-roll rollers are used when processing products made of copper, iron, steel, zinc, etc.;
four-roll designs equipped with an additional roller at the bottom to simplify the rolling process.

The most common rollers are three-roll and four-roll. Thus, three-rollers have the following distinctive properties:

a sheet whose width is less than 6 mm will slip between the shafts;
the sheet rolling speed should be a maximum of 5 m per minute;
it is difficult to operate the machine due to the lack of exact coordinates of the metal clamping point;
affordable price.

But four-roll rollers have the following characteristics:

Classification of machines

According to the bending method, rollers are:

segmental, where the pipes are bent under the action of one pulling segment;
mandrels, which deform thin-walled pipes;
spring. Thanks to the presence of a spring, the plastic bends without deformation;
crossbow, which are designed for pipes of one diameter or another.

Machines according to the method of use are divided into the following categories:

If you purchase or make a machine with your own hands for small household needs, then it is desirable that it have the following characteristics:

mobility and light weight;
compactness;
economical in terms of energy consumption, since a powerful device can damage home wiring.

Making a machine yourself

Naturally, assembling the machine with your own hands will be very expensive in terms of time and load, but if you plan to use it for minor repairs, then homemade assembly would be a more economical option than factory model, costing from 20 thousand rubles and above.

At self-assembly rollers, do not make such mistakes:

do not allow cracks to appear on the metal profile;
do not allow compression and tension of the surface at the point of load on the structural part;
Do not squeeze or deform parts before working.

Before you start working, prepare a project drawing, materials and details. The work steps will be as follows:

Here the product is ready. As you can see, rollers can be purchased at finished form, or do it yourself, having the required tools, drawings, and having the necessary skills.

Below we will tell you what rollers are, how three-roll models differ from four-roll models, and how to make them yourself.

Rollers: operating principle

The parts are bent through the action of the third rear shaft, and the fixing radius depends on the distance between the upper and rear shaft.

After roller processing the cross section of the metal is reduced, and it becomes longer under the influence of high metal temperature and degree of pressure.

To obtain a cylindrical product, the rear shaft must be adjusted parallel to the front one, and to make a cone, the rear shaft must be set at an angle relative to the front one.

The functions of modern rolling machines, home-made and factory-made, three-roll and four-roll, are as follows:

the ability to bend pipes up to 160 degrees;
working with metal pipes;
deformation of pipes regardless of their diameter.

Areas of application of machines

Roller mills are widely used in the production of things such as:

chimneys;
air ducts;
pipes;
ventilation systems;
gutters.

Thanks to its compact dimensions, rollers can be used anywhere, right at the construction site, and hand-held devices will not damage the polymer coating of the metal.

For the food industry, crusher-type rollers are used, and for the chemical industry, sheet bending, sheeting and others are used.

Features of machines for metal

plastic;
ductile metal;
rubber compounds.

You need to choose one or another machine depending on the thickness of the metal:

twin rollers include two parallel shafts, the upper one has a small cross-section and is made of high-strength steel, and the lower one has a large cross-section and is made of rubber-coated steel. Depending on the pressure force of the pipe, its outlet diameter is selected;
three-rollers can be symmetrical or asymmetrical, they are often used in the production of ventilation, round drains and radius parts. In addition, three-roll rollers are used when processing products made of copper, iron, steel, zinc, etc.;
four-roll designs equipped with an additional roller at the bottom to simplify the rolling process.

The most common rollers are three-roll and four-roll. Thus, three-rollers have the following distinctive properties:

a sheet whose width is less than 6 mm will slip between the shafts;
the sheet rolling speed should be a maximum of 5 m per minute;
it is difficult to operate the machine due to the lack of exact coordinates of the metal clamping point;
affordable price.

But four-roll rollers have the following characteristics:

Classification of machines

According to the bending method, rollers are:

segmental, where the pipes are bent under the action of one pulling segment;
mandrels, which deform thin-walled pipes;
spring. Thanks to the presence of a spring, the plastic bends without deformation;
crossbow, which are designed for pipes of one diameter or another.

Machines according to the method of use are divided into the following categories:

If you purchase or make a machine with your own hands for small household needs, then it is desirable that it have the following characteristics:

mobility and light weight;
compactness;
economical in terms of energy consumption, since a powerful device can damage home wiring.

Making a machine yourself

Naturally, assembling the machine with your own hands will be very expensive in terms of time and load, but if you plan to use it for minor repairs, then homemade assembly will be a more economical option than a factory model, costing 20 thousand rubles and more.

When assembling rollers yourself, do not make the following mistakes:

do not allow cracks to appear on the metal profile;
do not allow compression and tension of the surface at the point of load on the structural part;
Do not squeeze or deform parts before working.

Before you start working, prepare a project drawing, materials and details. The work steps will be as follows:

Here the product is ready. As you can see, rollers can be purchased ready-made, or made with your own hands, having the required tools, drawings, and having the necessary skills.

From sheet metal They make a lot of products - drainage systems, shaped parts for cladding or metal tiles, flashings for plinths, corners for structures made of corrugated sheets, etc. All this can be done by a special bending machine- for sheet metal. We’ll talk about how to make a sheet bending machine with your own hands in this article.

Types of sheet benders

All these devices are classified as sheet bending machines. The easiest way to make one with your own hands is the unit of the first group, a little more difficult - the third (rollers for sheet metal). So we’ll talk about them - from how to make a sheet bending machine with your own hands.

Simple manual

Shaped metal parts cost a lot of money. Even more than corrugated sheeting or metal tiles, so it makes sense to do the simplest machine for bending sheet metal, and with its help, make as many corners, ebbs and other similar parts as you need, and exclusively to your dimensions.

Bending machine - side view

If you're worried about appearance, then in vain. On sale today there is sheet metal not only galvanized, but also painted. In all designs, the sheet is fixed tightly, so that when working it does not slide on the table, which means that the paint does not rub off or get scratched. It is also not damaged in places of bending. So the products will look quite decent. If you try, they will look even better than what they sell on the market.

Powerful sheet bending machine from brands

For this sheet bending machine You will need a flat surface (table), preferably metal, three corners with a shelf width of at least 45 mm, and a metal thickness of at least 3 mm. If you plan to bend long workpieces (more than a meter), it is advisable to take wider shelves and thicker metal. You can use brands, but this is for bending sheets of metal of great thickness and length.

You will also need metal ones door hinges(two pieces), two large diameter screws (10-20 mm), wings on them, a spring. Will still be needed welding machine- weld the hinges and make holes (or a drill with a metal drill).

For a homemade sheet bender, a 70 mm brand was used - three pieces of 2.5 m each, two bolts of 20 mm in diameter, a small piece of metal 5 mm thick (for cutting jibs), a spring. Here's the procedure:

Two brands are folded, and grooves are cut into them at both ends for hinges. The edges of the recesses are beveled at 45°. The third tee is cut in the same way, only the depth of the recess is made a little larger - this will be the clamping bar, so it should move freely.
Weld the loops on both sides (weld on the front and back).
Two jibs on each side are welded to one of the brands (the one farthest from you, if you “open” them). They are needed so that you can install the clamping bar clamp bolt on them.
Weld the bolt nut to the jibs.
Install the clamping bar (third cut tee), weld metal plates with a hole in the middle in the upper part. The diameter of the hole is slightly larger than the diameter of the bolt. Center the holes so that they are on the same vertical line with the welded nut. Weld.
Cut the spring so that it raises the pressure bar by 5-7 mm. Pass the bolt into the “ear” of the clamping bar, put on the spring, and tighten the nut. After installing the same spring on the other side, the clamping bar rises on its own when unscrewed.
Weld two pieces of reinforcement to the screw head to serve as handles for tightening.
Weld a handle to the movable (closest to you) brand. That's it, you can work.

This option is very powerful - you can bend long workpieces and sheets of considerable thickness. Such scales are not always in demand, but they can always be reduced. The video suggests a similar design of a smaller size, but with a different fastening of the clamping bar. By the way, no one bothers you to also install a spring on the screw - it will be easier to raise the bar. What’s interesting about this design is that you can make beading on it, something that such devices usually cannot do.

From a corner with a different type of clamping bar

This model is welded from a thick-walled angle, the frame is made like an ordinary construction sawhorse, which is welded from the same angle. The handle is from a luggage trolley. The design of the screws is interesting - they are long, the handle is curved in the shape of the letter “L”. Convenient to unscrew/screw.

In this homemade machine There are many features for sheet metal bending:

Now let's move on to the design of the clamping bar (pictured above). It is also made from a corner, but is laid on the machine with an upward bend. To ensure that the bar does not bend during operation, reinforcement is welded on - metal jumpers. Small metal platforms are welded at both ends of the strip, in which holes are drilled for bolts.

Another important point- the edge that faces the fold is cut off - to obtain more acute angle bending

The clamping bar is placed on the machine, and a spring is placed in the place where the nut is installed. The handle is installed in place. If it does not press the bar, it is raised above the surface due to the elastic force of the spring. In this position, the workpiece is tucked under it, positioned, and pressed.

Place a spring under the hole, then a bolt

Not a bad option for home use. It will not be possible to bend thick metal, but tin and galvanized steel can be bent without difficulty.

Sheet metal rollers or roller bender

This type of sheet bending machine can have three types of drive:

manual;
hydraulic;
electric.

They make rollers for sheet metal with manual or electric drive with their own hands. Manual ones have 3 shafts, electric ones can have 3-4, but usually there are also three.

This machine needs a good solid foundation. This could be a separate bed or some kind of workbench or table. The basis of the structure is rolls. They are made the same size. The two lower ones are installed permanently, the upper one is movable, so that in the lower position it is located between the rollers. By changing the distance between the lower rollers and the upper one, the radius of curvature changes.

The machine is set in motion using a handle attached to one of the shafts. Then the torque is transmitted to other rollers through sprockets. They are selected so that the rotation speed is the same.

If the equipment is intended to produce pipes, the upper roller on one side is made removable, with a quick fixation system. Once the sheet is rolled into a pipe, there is no other way to pull it out.

When carrying out repairs and construction work in the private sector there is often a need to manufacture curved metal structures. They are used to create a frame for canopies, awnings, roofs of houses and gazebos. Rollers for profile pipe. These are devices that can be purchased in specialized stores or made with your own hands. Let's consider the purpose of these devices, their varieties and specifications.

Only rolling on a special machine is a way to achieve a similar result. Rollers are a mechanism consisting of several metal shafts and an energy source that drives them.

Types of rollers

To give the rolled product the required shape, devices with the same mechanical part and different drives are used.

The choice of energy source depends on several factors:

how much load is required to bend the metal;
how often the equipment will be used;
under what conditions the pipe bender is planned to be used;
own knowledge, experience in the field of design and working with iron.

Let's briefly look at the features of each type of drive.

Hydraulic

Designs of this type are the most powerful and productive. As a rule, they are used by factories and plants involved in the mass production of curved profiles. Hydraulics are difficult to self-installation, but it creates a force sufficient to bend several large-section pipes at once.

At home, constructing a hydraulic profile bender is economically justified if you plan to produce tens or hundreds of thick arched profiles.

Mechanical/lever

The products are portable and lightweight. They are easy to carry from place to place and transport in the back. Increased pressure on the drive device is achieved by increasing the length of the lever. However, only profiles with a cross-section of no more than 40×20 mm can be bent manually. These parts are suitable for building the roof of a house and yard buildings. Greenhouses covered with cellular polycarbonate are made from arched profiles.

Electrical

Using an electric motor to drive workpieces through shafts not only speeds up the pipe bending process, but also eliminates home handyman from hard physical labor. Performance electrical devices high with low financial costs.

Assembling a machine on your own requires knowledge in the field of mechanics, electrical engineering and kinematics. Please pay attention to safety issues.

Operating principle of rollers

Rolling a profile pipe is the process of giving it a bend of a certain radius. To achieve this, you need to place the workpiece between the rollers, which are located below and above. The workpiece is fed into the device and pressed down from above. After this, the shafts begin to rotate, moving the pipe forward and deforming it in the direction of the upper shaft.

If the degree of bending is not sufficient for the project, then the degree of pressure is increased. The product is rolled through rollers until the desired shape is achieved.

How to use rollers

This device consists of several static and moving parts:

The base is a strong, heavy and stable frame to which all other components and mechanisms are attached.
There are rollers on the frame that act as receiving and feeding devices. The transmission to the power plant is connected to the rollers.
A clamping device is attached to the base to regulate bending parameters. As a rule, manufacturers use a threaded clamp.
A guide made of metal sheet, reinforcement or steel profile is fixed to the frame. This part is necessary to ensure that the workpiece does not bend in the horizontal direction.

Regardless of the energy source supplied to the guide rollers, all devices operate in the same way. After turning on the equipment, the end of the profile is inserted into the hole between the rollers and moved forward. The captured workpiece passes along the shafts, where it is deformed. To reduce the radius, the clamp is tightened and the arch is run again.

Is it better to buy or make it yourself?

The products produced at the factory have one thing in common - a high price. It far exceeds the costs of purchasing ready-made arches or ordering this service from professionals. With a competent approach to business homemade pipe benders superior in quality to factory analogues.

The decision about whether to make an expensive purchase or make a machine yourself should be made after studying market conditions and assessing your capabilities.

Which ones are on the market?

The hardware market provides a wide selection, varying in different parameters. Machines can have several rollers and even directions for simultaneous bending of several workpieces. Work zone equipped with a folding or adjustable shaft.

The drive is output to the upper and lower shafts or only to one level. Electrical and hydraulic devices provide the possibility of manual rotation with an indication of how much force is required for this.

Modern models of pipe benders are classified according to the following criteria:

actuator;
dimensions;
type of metal being processed;
profile wall thickness;
diameter (mm) of rollers;
maximum length of workpieces.

Almost all machines have the option of reversing the rotation of the rolling mechanism.

DIY assembly

Pipe bending rollers are a simple device. You can even make it from scrap materials left over after renovation and construction. In most cases, when deciding how to make rollers, novice craftsmen tend to choose a mechanical type design. It is easy to design and assemble using welding, which is found in every home.

The small-sized machine is easy to move around the site; there is no need to build a separate room for it.

Drawing

Before making a high-quality and functional machine for bending profiles, it is necessary to make detailed drawings, the dimensions of all parts should be applied with high accuracy.

Roll patterns can be made on graph paper or on a computer. The choice depends on design skills. Based on the drawn up drawings, the need for building materials and tools. An estimate is made, equipment is selected and missing property is purchased.

Materials and tools

To assemble homemade rollers, you will need the following tools and consumables:

welding machine;
grinder or milling cutter with discs for metal;
roulette;
electric drill;
set of screwdrivers and wrenches;
square;
core;
oil level;
hardware (angles, bolts, nuts, rivets);
channel or I-beam;
blanks for shafts;
profile pipes.

When selecting material for construction, you should remember that metals and alloys for rollers must be much stronger than the steel of profile pipes.

What is included in the design

The bed is made of thick and heavy rolled steel.

The strength and weight of the base must correspond to the force applied when rolling the profiles. The assembled frame must be stable and strong so as not to swing during operation.

The clamping system is assembled in the shape of the letter “P”. A threaded hole is made on the top crossbar to create clamping force. Another option is to weld the nut over the round hole. Subsequently, a bolt is inserted into it to adjust the clearance between the rollers.

The rollers themselves are equipped with rolling bearings, which are mounted on durable axles. The rollers are turned on a lathe and undergo a hardening cycle in oil.

The drive is made from bicycle sprockets and a chain. The sprockets are welded to the driven and drive shafts, and then connected by a chain. A gate with sufficient leverage is welded onto the drive sprocket.

Filling with sand or water?

When the workpieces are given a strong bend, they are flattened and the cross-section geometry is disrupted. In order to prevent this, hollow profiles are filled with dense material that does not change volume under pressure.

The most simple solution is filling the blanks with sand. It is spilled with water, compacted, and then plugs are welded to the ends.

With water it is more difficult, since the plugs must be sealed. If the assembly takes place in winter, then the best solution the pipes will be filled with water, closed with plastic plugs and frozen. This method is used in the manufacture of wind musical instruments.

Spring selection

Springs are used to reduce the impact of vibration from the electric motor on the rolling system. With strong vibration, workpieces may shift along the horizontal axis. The springs must be stiff to prevent the engine from rocking and at the same time reduce shaking. It is recommended to use at least 4 springs to fix the motor frame.

Cut and cook

The roller manufacturing process is carried out in the following sequence:

Taking measurements and applying markings in accordance with the diagrams.
Cutting rolled products into blanks, cleaning the field for welding.
Turning and hardening of shafts, installing bearings in them, attaching sprockets, securing to an axle.
Welding the frame with a rolling and pressing mechanism.
Drive installation. It can be permanent or removable.
Checking the functionality of the machine.

Finally, the metal is cleaned from rust, primed and painted. Moving parts are lubricated.

Process video

Watch a video of the work self-production rollers will help novice craftsmen easily cope with this work.